Panel roller

ABSTRACT

A roller which fits into and rides a panel along a guide channel has a molded synthetic roller head and a molded synthetic roller shaft. The head and the shaft are made separately from and then attached to one another. The roller head has a center opening and the roller shaft has an end part which is trapped in the center opening of the roller head without requiring the use of separate fasteners.

FIELD OF THE INVENTION

[0001] The present invention relates to a roller used to roll a panel along a guide channel for the panel.

BACKGROUND OF THE INVENTION

[0002] Guide rollers for panels are known in the prior art. These guide rollers are often used in a rolling door construction such as for example, a hinged garage door. The head of the roller is trapped in a guide channel beside the garage door and the shaft of the roller is secured by some type of bracket to the inside of the garage door.

[0003] The known guide rollers for rolling doors have a metal construction with the head and shaft of the roller being secured by some type of a mechanical fastener.

[0004] On a relatively large door the number of rollers required add to the weight of the door due to the metal construction of the rollers. Also the rollers themselves are often susceptible to rusting particularly when they face outdoor weather conditions.

SUMMARY OF THE PRESENT INVENTION

[0005] The present invention provides a roller which is light in weight, which is easy to assembly and which does not deteriorate due to climatic conditions.

[0006] More particularly the roller of the present invention which fits into and rides a panel along a guide channel comprises a molded synthetic roller head and a molded synthetic roller shaft. The head and the shaft of the roller are made separately from and then attached to one another. The roller head has a center opening and the roller shaft has an end part which is trapped in the center opening of the roller head. The can be done in a number of different ways which through the synthetic construction of the roller does not necessitate the use of a separate mechanical fastener.

[0007] The molded construction of the roller provides very accurate roller parts at a very affordable price. Furthermore, the synthetic construction of the roller makes it extremely light in weight and durable compared to prior art metal rollers.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above as well as other advantages and features of the present invention will be described in greater detail according to the preferred embodiments of the present invention in which;

[0009]FIG. 1 is perspective view of a truck trailer rolling door as seen from the outside of the truck trailer according to a preferred embodiment of the present invention;

[0010]FIG. 2 is a further perspective view of the truck door of FIG. 1 when seen from the inside of the truck trailer;

[0011]FIG. 3 is an end view of some of the panels fitted with guide rollers to ride along a guide channel from the truck trailer door of FIGS. 1 and 2;

[0012]FIG. 4 is a partially exploded perspective view of the panels from the truck trailer door of FIGS. 1 and 2 when not fitted with the roller and when away from the roller guide;

[0013]FIG. 5 is an enlarged end view of the connection of two of the panels from the door of FIG. 4;

[0014]FIG. 6 is perspective view of one of the rollers from the truck door of FIG. 3;

[0015]FIG. 7 is a front end view of the roller head from the roller of FIG. 6;

[0016]FIG. 8 is a side view of the roller head of FIG. 7;

[0017]FIG. 9 is a perspective view of the roller shaft from the roller of FIG. 6 when removed from the roller head;

[0018]FIG. 10 is a side view of the roller shaft of FIG. 9;

[0019]FIG. 11 is a side view of the roller of FIG. 6; and

[0020]FIG. 12 is a sectional view through the roller head and the inner end of the shaft of the roller of FIG. 11.

DETAILED DESCRIPTION ACCORDING TO THE PREFERRED EMBODIMENTS OF THE PRESENT INVENTION IN WHICH

[0021]FIG. 1 shows the rear end of a truck trailer. The truck trailer is opened and closed by a rolling door generally indicated at 1. This rolling door comprises a plurality of panels 3 hingedly secured to one another. The panels preferably have a resin construction.

[0022]FIG. 2 shows that the trailer to the inside of door 1 is provided with a pair guide channels 5 to each side of the door.

[0023] As will be seen in FIG. 3 of the drawings rollers 11 ride the panels 3 along the guide channels 5.

[0024]FIGS. 4 and 5 of the drawings show that each of the panels 3 is provided to one end with a hollow head 7 and to the other end with an undercut opening 11. Head 7 slides into opening 11 to provide a hinged connection between the adjacent panels as shown in FIG. 5 of the drawings. The hollow head 7 provides an opening 9 for receiving one of the rollers 11 between each of the panels at opposite sides of the door.

[0025] The roller itself is best described having reference to FIGS. 6 through 12 of the drawings. These figures show that roller 11 comprises a roller head 13 and a roller shaft 14.

[0026] As can be seen from FIGS. 7 through 10 the roller head 13 and the roller shaft 14 are two completely separate components. They are both made in their own molding operation. They both have a synthetic construction and preferably have a fiberglass resin composite construction. The resin provides the durability and the binder for the fiberglass which provides rigidity and strength to each of the components.

[0027]FIG. 7 shows that the roller head 13 has a center opening 15 which is bordered by a flat front face 17. Located around and protruding forwardly of the flat face 17 is a rounded rim 19 on which the roller rides.

[0028] Provided to the rear side of roller 13 is a hollow neck 21 which aligns with the center opening 15 in the roller head.

[0029] The roller shaft 14 is designed to snap lock with the roller head. More particularly, shaft 14 includes an end part generally indicated at 24. This end part comprises a flange 25 and a slot 27 through the end part 24 of the shaft. Flange 25 has a front tapered or cam surface 29.

[0030] Located farther along the roller shaft spaced from flange 29 is a ring like projection 33 expanding radially on the main body of the shaft. The ring like projection 33 is separated from flange 25 by a body part 31 of the shaft.

[0031] In its relaxed condition, as shown in FIG. 12 of the drawings the end part 24 and in particular the flange 25 of the end part has a diameter greater than that of the center opening in the roller head and the opening through collar or neck 21 on the back of the roller head. However, the end part 24 is collapsible inwardly due to the provision of slot 27. When the end part is collapsed the diameter of the flange is less than that of opening 15 in the roller head allowing the end part of the shaft to be pushed through neck 21. The cam front surface 29 of the flange eases the fitting of the end part through the neck.

[0032] Once the end part of the shaft has been pushed into the FIG. 12 position the resiliency of the glass and resin material of the shaft causes the flange to expand back to its normal configuration locking flange 25 against the front face 17 of the roller head.

[0033] The roller head will not slide completely along the length of the roller shaft because of the interference provided by the ring like projection 33 on the shaft facing the neck 21 on the roller head. However, it should be noted that the body part 31 on the shaft between the flange 29 and the projection 33 is slightly longer than neck 21 allowing some sliding of the roller head axially of the shaft. Furthermore, when the head and the shaft are locked together as shown in FIG. 12 the shaft is allowed to rotate relative to the roller. Therefore not only is the head of the roller allowed to roll along channel or track 5 but in addition the shaft is allowed to rotate relative to the roller head. This provides a very low friction rolling action between the door and the roller head without requiring the use of ball bearings and the like. Further it should be noted that the material itself provides a very low co-efficient of friction to enhance the rolling of the door.

[0034] Added to all of the above is the feature that the roller head is allowed to have a limited amount of axial sliding along the shaft. This compensates for possible variances in the spacing between the guide tracks to either side of the door.

[0035] All of the above features are accomplished without having to provide anything in the way of additional mechanical fasteners between the roller head and the roller shaft.

[0036] According to another embodiment of the invention the roller head and the roller shaft are once again made in separate molding operations but secured to one another by a shrink fitting of the head to the end of the shaft. This again eliminates the necessity for separate mechanical fasteners to secure the head and the shaft.

[0037] As will be understood from reviewing FIGS. 4 and 6 of the drawings the shaft 14 of each roller easily inserts into the hollow opening 9 which is provided at each hinge connection of adjacent panels to one another.

[0038] The panel insertion end of the shaft is preferably provided with a taper 35 as shown in FIGS. 6, 10 and 11 of the drawings. This eases the insertion of the shaft into the panel joint.

[0039] When using a synthetic roller made from separate molded components as described above not only is the assembly of the roller itself extremely easy and efficient but in addition the weight of the truck door or any other type of rolling door to which the roller is fitted is extremely light. This allows the overall door to be more easily managed in comparison to a rolling door using for example a series of metal rollers. Furthermore, a rolling door incorporating synthetic rollers as described does not require lubrication of the rollers nor does it require the replacement of the rollers due to rusting problems as found in prior art rolling doors.

[0040] Although various preferred embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that variations may be made without departing from the spirit of the invention or the scope of the appended claims. 

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A roller for fitting into and riding a panel along a guide channel, said roller comprising a molded synthetic roller head and a molded synthetic roller shaft made separately from and attached to said roller head, said roller head having a center opening and said roller shaft having an end part which is trapped in said center opening of said roller head.
 2. A roller as claimed in claim 1 wherein said roller shaft is attached to said roller head without additional locking parts.
 3. A roller as claimed in claim 1 wherein both said roller head and said roller shaft have a fiberglass and resin composite construction.
 4. A roller as claimed in claim 1 wherein said roller head is shrink fitted to said end part of said roller shaft.
 5. A roller as claimed in claim 1 wherein said end part of said roller shaft includes an end flange and a slot across said end part, said end flange having a diameter which is greater than that of said center opening of said roller head and said end part of said shaft being resiliently collapsible at said slot for fitting said end flange through said center opening.
 6. A roller as claimed in claim 5 wherein said roller head is rotatable on said roller shaft.
 7. A roller as claimed in claim 4 wherein said end flange has a cam shaped outer edge to ease fitting of said flange through said center opening of said roller head.
 8. A roller as claimed in claim 4 wherein said roller head has a front side and a rear side, said rear side including a rearwardly protruding hollow neck aligned with said center opening in said roller head, said end part of said roller shaft fitting through said hollow neck to lock at the front side of said roller head, said front side of said roller head having a face area bordered by a round rim which protrudes forwardly of said face region of said roller head.
 9. A roller as claimed in claim 8 wherein said roller shaft includes a radial shaft projection spaced from said end flange by a body part of said roller shaft, said body part being elongated relative to said hollow neck allowing said roller head to slide axially of said roller shaft where said roller head is trapped between said end flange and said shaft protrusion.
 10. A roller as claimed in claim 1 wherein said roller shaft has a tapered panel insertion end opposite said end part of said shaft trapped in said roller head. 